MAINTENANCE AND

CHAPTER
TROUBLESHOOTING

In This Chapter ...

7
Maintenance and Inspection . . . . . . . . . . . . . . . . .72
Basic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Expected Life of Replacement Components . . . . . . . . . . . . . . . .73
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Fault & Warning Message Table . . . . . . . . . . . . . . . . . . . . . . . . .74
Fault Message Potential Causes and Corrective Actions . . . . . . . .75
Warning Message Potential Causes and Corrective Actions . . . . .79
Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .710
 Chapter 7: Maintenance and Troubleshooting

Maintenance and Inspection

SureServo AC servo drives are based on solid state electronics technology.
Preventive maintenance is required to make sure the drive functions properly and
has a long life. We recommend that periodic maintenance and inspection of the
servo drive be performed by a qualified technician. Always turn off the AC input
power to the unit before any maintenance and inspection.

WARNING: AC input power must be disconnected before performing any maintenance.

Do not connect or disconnect wires or connectors to the servo drive or motor while
power is applied to the circuit. Make sure that the internal capacitors have fully
discharged (wait for the Charge LED to go off) before performing the maintenance
and inspection! Maintenance must be performed by a qualified technician only.

WARNING: A charge with hazardous voltages may still remain in the DC-link capacitor
even if the power has been turned off. To avoid personal injury, do not remove the
cover of the AC servo drive. There are no user serviceable parts inside the drive.

Basic Inspection
Item Inspection Content
Periodically inspect the mounting screws for the servo drive, motor shaft, terminal block, and
the connection to mechanical system. Tighten screws as necessary; they may loosen due to
vibration and temperature variation.
Make sure that oil, water, metallic particles, or any foreign objects do not fall inside the servo
General drive, motor, control panel, or ventilation slots and holes.
Inspection
Make sure that the servo drive control panel has been installed correctly, and that it is free
from airborne dust, harmful gases, or liquids.
Make sure that all wiring instructions and recommendations are followed to prevent damage
to the drive and/or motor.
Make sure control switch is OFF.
Make sure that all wiring terminals are correctly insulated.
Make sure that all wiring is correct to prevent damage and/or malfunction.
Visually check to make sure that there are no unused screws, metal strips, or any conductive
Inspection or flammable materials inside the drive.
before To avoid electric shock, be sure to connect the servo drive ground terminal to the control
operation panel ground terminal. Before making any connection, wait 10 minutes for internal
capacitors to discharge after power is disconnected.
(Control
power not Never put flammable objects on servo drive or close to the external regenerative resistor.
applied) If the electromagnetic brake is being used, make sure that it is correctly wired.
If required, use an appropriate electrical filter to eliminate noise to the servo drive.
Make sure that the external applied voltage to the drive is correct and matched to the controller.
Make sure that the cables are not damaged, stressed excessively, or loaded heavily. When the
motor is not running, check the cables and connections for damage, fraying, or over extension.
Inspection Check for abnormal vibrations and sounds during operation. If the servo motor is vibrating or
during there are unusual noises while the motor is running, shut the motor down. Disconnect input
power before troubleshooting the motor.
operation
Make sure that all user-defined parameters are set correctly.
(Control
power Reset parameters when the servo drive is off to prevent servo system malfunction.
applied) Check the power indicators and LED display for abnormal conditions.

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 Chapter 7: Maintenance and Troubleshooting

Maintenance
Use and store servo system in a clean, dry, and normal-temperature environment.
Periodically clean the surfaces and panel of servo drive and motor.
Periodically check the resistance of the insulation with Meg-ohmmeter. The
insulation resistance should measure at least 100 Meg-Ohms at 500 VDC and
should be tested with a power cable connector properly connected to the motor.
Periodically check the DC BUS filter capacitors and precharge relays after the
warranty period, and replace if necessary.
Periodically check the conductors or insulators for corrosion and/or damage.
Do not disassemble or damage any mechanical part when performing
maintenance.
Periodically clean off any dust and dirt with a vacuum cleaner, especially the
ventilation ports and printed circuit boards. Always keep these areas clean;
accumulation of dust and dirt can cause overheating and component failures.

WARNING: To prevent serious injury or equipment damage, inspection and

replacement of board-level components should be performed by qualified repair
technicians experienced in board-level maintenance and repair.

Expected Life of Replacement Components

DC BUS Filter Capacitor
DC BUS filter capacitor life varies according to ambient temperature and
operating conditions. Excessive ripple currents will shorten capacitor life. The
expected life is ten years when properly used in a clean, dry, air-conditioned
environment.

Precharge Relay
The contacts will wear due to switching current; the common expected relay life
is 100,000 operations.

Cooling fan (SVA-2100 and SVA-2300 Models Only)

The cooling fan should be checked periodically for adequate air flow, which is
essential to prevent damage to the power stage. Replace fan immediately if it is
vibrating or making unusual noises.

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 Chapter 7: Maintenance and Troubleshooting

Troubleshooting
Fault & Warning Message Table
Once a fault or error is detected, the corresponding protective fault functions will
be activated and the fault messages will be displayed.

Fault/Warning Messages
Display Fault/Warning Name TYPE Fault/Warning Description
Main circuit current is higher than 1.5 multiple of motor's
ALE 01 Overcurrent Fault
instantaneous maximum current value.
Main circuit voltage has exceeded its maximum allowable
ALE 02 Overvoltage Fault
value. (Main circuit voltage is higher than specification.)
Main circuit voltage has fallen below its minimum value.
ALE 03 Undervoltage Fault
(Main circuit voltage is lower than specification.)
The motor's operating temperature is higher than the
ALE 04 Motor overheated Fault
upper-limit of the specification.
ALE 05 Regeneration error Fault Regeneration control operation is in error.
ALE 06 Overload Fault Servo motor and drive are overloaded.
ALE 07 Overspeed Fault Motor's control speed exceeds the limit set in P1-55.

ALE 08 Abnormal
command
pulse control
Fault
Input frequency of pulse command exceeds the limit of its
allowable set value.
Position control deviation value exceeds the limit of its
ALE 09 Excessive deviation Fault
allowable set value.
ALE 10 Watch dog execution time out Fault Watch dog execution time out.
ALE 11 Position detector error Fault Pulse signal is in error.

ALE 12 Internal Components

Require Calibration
Fault Internal Components Require Calibration

ALE 13 Fault stop Fault Fault stop switch is activated.

ALE 14 Reverse limit error Fault DI setting 22 reverse limit switch is activated.
ALE 15 Forward limit error Fault DI setting 23 forward limit switch is activated.
ALE 16 IGBT temperature error Fault IGBT is overheated.
ALE 17 Memory error Fault EE-PROM write-in and read-out is in error.
ALE 18 DSP communication error Fault DSP communication is in error.
ALE 19 Serial communication error Fault RS232/422/485 communication is in error.
ALE 20 Serial communication time out Fault RS232/422/485 communication time out.
ALE 21 Command write-in error Fault Control command write-in error.
ALE 22 Input power phase loss Fault One phase of the input power is lost.

ALE 23 At Overload Output

Warning Threshold
Warn Motor overload exceeds the time % set in P1-56.

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 Chapter 7: Maintenance and Troubleshooting

Fault Message Potential Causes and Corrective Actions

ALE 01: Overcurrent
Potential Cause Checking Method Corrective Actions
Check the wiring connections between
Short-circuit at drive
drive and motor, and check cables for Repair short-circuit.
output
shorts.
Make sure the connections between Follow the wiring steps in the user manual to
Motor wiring error
the motor and drive are correct. reconnect wiring.
Control parameter Check if the set value exceeds the Change the setting back to factory default,
setting error factory default setting. reset, and adjust the parameter setting again.
Control command Check if the control input command is Make sure that input command frequency is
setting error unstable (fluctuating too much). stable and activate filter function.
IGBT error Heat sink overheated. Call Technical Support: 770-844-4200

ALE 02: Overvoltage

Potential Cause Checking Method Corrective Actions
The main circuit voltage has
Use voltmeter to check whether the
exceeded its maximum
input voltage falls within the rated Use correct power supply.
allowable value
input voltage.
(incorrect power input).

ALE 03: Undervoltage

Potential Cause
The main circuit voltage has
fallen below its minimum Check for proper input voltage wiring.
value.
No input voltage at main
circuit.
Input power error
(Incorrect power input)
Checking Method
Use voltmeter to check whether input
voltage at main circuit is normal.
Use voltmeter to check whether the
input voltage is within the specified
limit.
Corrective Actions
Correct input wiring as needed.
Check input power supply, including
switches and fuses.
Use correct power supply.

ALE 04: Motor Overheated

Potential Cause Checking Method Corrective Actions
Use thermometer to check the motor
Re-size the capacity of motor and drive or
Servo system is temperature (motor external temperature
reduce system demands (decrease speed,
overloaded. should not be above 158F), and check
increase accel/decel time).
if servo system is overloaded.

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 Chapter 7: Maintenance and Troubleshooting

ALE 05: Regeneration Error

Potential Cause Checking Method Corrective Actions
Regenerative resistor is Check the regenerative resistor wiring
Connect regenerative resistor as needed.
not connected. connections.
Confirm the parameter setting and
Parameter setting error Correctly reset parameter again.
specifications of regenerative resistor.

ALE 06: Overload

Potential Cause Checking Method Corrective Actions
The drive has exceeded
its rated load during Check for drive overloading. Increase motor capacity or reduce load.
continuous operation.

Control system parameter Check for mechanical vibration. Adjust gain value of control circuit.
setting is incorrect. Accel/decel time setting is too fast. Increase accel/decel time setting.
Motor and encoder Check the wiring of U, V, W and
Make sure all motor wiring is correct.
wiring error. encoder.

ALE 07: Overspeed

Potential Cause Checking Method Corrective Actions
Speed input command is
Use signal detector to detect if input Make sure that input command frequency is
not stable (too much
signal is abnormal. stable and activate filter function.
fluctuation).
Over-speed parameter Check if over-speed parameter setting
Correctly set over-speed parameter setting.
setting is defective. value is too low.

ALE 08: Abnormal Pulse Control Command

Potential Cause Checking Method Corrective Actions
Pulse command
Use pulse frequency detector to
frequency is higher than Correctly set the input pulse frequency.
measure input frequency.
rated input frequency.
Incorrect pulse stream for Use oscilloscope to view incoming
Correct incoming pulse stream.
quadrature input. pulse stream.

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 Chapter 7: Maintenance and Troubleshooting

ALE 09: Excessive Deviation

Potential Cause Checking Method Corrective Actions
Maximum deviation Check the maximum deviation
Increase parameter setting value.
parameter setting is too small. parameter setting.
Gain value is too small. Check if the setting value is correct. Correctly adjust gain value.
Torque limit is too low. Check torque limit value. Correctly adjust torque limit value.
Reduce external applied load or re-size
There is an overload. Check for overload condition.
the motor capacity.
Increase Accel/Decel times to see if Increase Accel/Decel or resize motor
Profile is too demanding.
ramp is too steep. capacity.
One or more Position Velocity
Check whether the value of any Set all of the Position Velocity parameters
parameter is set greater than
P2-36 ~ P2-43 is greater than less than or equal to the Maximum
the Maximum Velocity Limit
the value of P1-55. Velocity LImit.
parameter.

ALE 10: Watch Dog Execution Time Out

Potential Cause Checking Method Corrective Actions
If there are any abnormal conditions after
Watchdog execution error. Check and reset the power supply. resetting the power supply, call Technical
Support: 770-844-4200

ALE 11: Position Dectector Error

Potential Cause Checking Method Corrective Actions
Check to make sure the wiring is
correct and that all connections are
Encoder wiring error. Correct any wiring errors.
tight; refer to the wiring information
in this user manual.
Using oscilloscope, check encoder for
Encoder is damaged. Repair or replace motor.
damage.

ALE 12: Internal Components Require Calibration

Potential Cause Checking Method Corrective Actions
If the error does not clear after restoring
Internal component
Restore to default configuration. the drive to default settings, contact
calibration
Technical Support: 770-844-4200

ALE 13: External Fault Stop

Potential Cause Checking Method Corrective Actions
Fault stop input is activated. Check if fault stop switch is On or Off. Clear and reset fault input.

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 Chapter 7: Maintenance and Troubleshooting

ALE 14: Reverse Limit Error

Potential Cause Checking Method Corrective Actions
Reverse limit switch is Move load in forward direction to
Check if reverse limit switch is On or Off.
activated. deactivate limit switch, and reset fault.
Check the value of control parameter Modify parameter setting and re-size
Servo system is not stable.
setting and load inertia. motor capacity.

ALE 15: Forward Limit Error

Potential Cause Checking Method Corrective Actions
Forward limit switch is Move load in reverse direction to
Check if forward limit switch is On or Off.
activated deactivate limit switch, and reset fault.
Check the value of control parameter Modify parameter setting and re-size
Servo system is not stable.
setting and load inertia. motor capacity.

ALE 16: IGBT Temperature Error

Potential Cause Checking Method Corrective Actions
The drive has exceeded its
Check for an overload, or if the motor Increase motor capacity or reduce
rated load during continuous
current is too high. load.
operation.
Short-circuit at drive output Check the drive input wiring. Make sure it is wired correctly.

ALE 17: Memory Error

Potential Cause Checking Method Corrective Actions
If the error does not clear after resetting
Data error in Memory read-
Reset parameter or power supply. the parameter or power supply, contact
out / write-in.
Technical Support: 770-844-4200.

ALE 18: DSP Communication Error

Potential Cause Checking Method Corrective Actions
If the error does not clear after resetting
Control power error. Check and reset control power. the power supply, contact Technical
Support: 770-844-4200.

ALE 19: Serial Communication Error

Potential Cause
Communication parameter
setting is not correct.
Communication address is
not correct.
Communication setting
value is not correct.
Checking Method Corrective Actions
Check communication parameter
Set parameter setting to correct value.
setting.
Set communication address to correct
Check communication address.
value.
Set communication setting to correct
Check read-out and write-in value.
value.

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 Chapter 7: Maintenance and Troubleshooting

ALE 20: Serial Communication Time Out

Potential Cause
Set value in time out
parameter is not correct.
Not receiving
communication command.
Checking Method
Check the time out parameter setting.
Check whether communication cable
is loose or broken
Corrective Actions
Set parameter to correct value.
Tighten or repair communication cable.

ALE 21: Command Write-in Error

Potential Cause Checking Method Corrective Actions
If the error does not clear after resetting
Control power supply error. Check and reset control power supply. the power supply, contact Technical
Support: 770-844-4200.

ALE 22: Input Power Phase Loss

Potential Cause Checking Method Corrective Actions
Check for poor input power line
Input power error. connection, or for possible loss of Correctly connect three-phase power.
phase on input power line.

Warning Message Potential Causes and Corrective Actions

ALE 23 (Warning): At Overload Output Warning Threshold
Potential Cause Checking Method Corrective Actions
Overload time exceeds the
This ALE is a warning, rather than a
Overload Output Warning Check value of P1-56 overload time.
fault. It does not have to be cleared.
Treshold.

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 Chapter 7: Maintenance and Troubleshooting

Clearing Faults
Display Fault Name How to Clear Fault
ALE 05 Regeneration error Turn Alarm Reset (DI signal) ON to clear the fault.
ALE 06 Overload Turn Alarm Reset (DI signal) ON to clear the fault.
ALE 07 Overspeed Turn Alarm Reset (DI signal) ON to clear the fault.
Abnormal pulse control
ALE 08 command
Turn Alarm Reset (DI signal) ON to clear the fault.

ALE 09 Excessive deviation
ALE 10 Watch dog execution time out
ALE 11 Position detector error
Internal Components
ALE 12 Require Calibration
Turn Alarm Reset (DI signal) ON to clear the fault.
This fault information cannot be cleared.
This fault condition can be removed (or reset) only by cycling
control power to the servo drive.
Restore to default configuration.

This fault information can be removed automatically by

ALE 13 Fault stop
resetting Fault Stop Input (DI signal).
Move load in forward direction to deactivate limit switch.
ALE 14 Forward limit error Turn Alarm Reset (DI signal) ON or turn off the servo drive to
clear the fault.
Move load in forward direction to deactivate limit switch.
ALE 15 Reverse limit error Turn Alarm Reset (DI signal) ON or turn off the servo drive to
clear the fault.
ALE 16 IGBT temperature error Turn Alarm Reset (DI signal) ON to clear the fault.
ALE 17 Memory error Turn Alarm Reset (DI signal) ON to clear the fault.
ALE 18 DSP communication error Turn Alarm Reset (DI signal) ON to clear the fault.
ALE 19 Serial communication error Turn Alarm Reset (DI signal) ON to clear the fault.
ALE 20 Serial communication time out Turn Alarm Reset (DI signal) ON to clear the fault.
ALE 21 Command write-in error Turn Alarm Reset (DI signal) ON to clear the fault.
ALE 22 Input power phase loss Turn Alarm Reset (DI signal) ON to clear the fault.
At Overload Output Warning This ALE is a warning rather than a fault,
ALE 23 Threshold and therefore does not have to be cleared.
For drive firmware v2.10 and higher, active faults can be reset from the keypad.
Press and hold the UP and DOWN Arrow Keys simultaneously for two seconds to clear the fault.

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